Future Efficiency Regulations May Focus on Systems

Last year, the Department of Energy (DoE) held framework meetings to investigate how efficiency regulations might be established for motor-driven systems in fan, pump, and air compression applications. Since industrial motor efficiency is nearing its theoretical maximum, system efficiency is the next logical focus for improvement. Recent regulations for 1-HP to 500-HP three-phase motors, as well as the Small Motor Rule for 0.25-HP to 3-HP single- and three-phase open drip-proof motors, are expected to complement the system regulations.

The issues the DoE has been discussing include how efficiency would be measured, what components would be in the system, and what installation practices should be followed. Some of these systems are already regulated in Europe, so harmonization with those standards may be a possibility. Industry trade associations for these groups are also involved in the discussions.

There is likely to be a multi-year study before the DoE proposes any standards. However, new negotiated regulation procedures may speed along the process.

"To figure out the life cost of a motor, simple calculations use hours operated, motor energy consumption to see the cost of energy over a 20 year life for the motor. We know the motor purchase price and another guide gives us the average repair cost for replacing motor bearings and cleanup in the middle of the motor's life"

John, thanks now I got it. it's a best assumption by considering the various factors and neglecting the fact that Motor won't stop work in between.

To figure out the life cost of a motor, simple calculations use hours operated, motor energy consumption to see the cost of energy over a 20 year life for the motor. We know the motor purchase price and another guide gives us the average repair cost for replacing motor bearings and cleanup in the middle of the motor's life. These are the 3 slices of the pie.

"If I understood better how I might be able to post a pie chart here, the one would show motor purchase at about 2%, electricity at around 97% and maintenance of the motor at a little less than 1% over its life cycle. We created this graphic about 25 years ago. A recent study by NEMA and MIT showed the lifetime carbon footprint from a motor as about 99% from electricity usage"

John, thanks for the details, but still not convinced how you figure out these values.

You bring up two important items. The first is changing the paradigms for purchasing folks. We historically have rewarded them for saving money on purchases, but that does not play well with today's idea to increase productivity and reduce downtime and energy consumption. Its like the old oil filter commercial, you can pay a little more now or a lot more later. Purchasing folks need to be on the team to know that cutting corners has a big effect on the bottom line.

If I understood better how I might be able to post a pie chart here, the one would show motor purchase at about 2%, electricity at around 97% and maintenance of the motor at a little less than 1% over its life cycle. We created this graphic about 25 years ago. A recent study by NEMA and MIT showed the lifetime carbon footprint from a motor as about 99% from electricity usage.

"In the past, OEMs would concentrate on first cost, specifying lower efficiency less expensive motors and components. Users have demanded a more robust machine that increases productivity and lower life cycle cost. The life cost of a motor is only 2%; over 97% is energy cost."

John, how and on what parameters these figures have arrived. Actually for a motor investment si more and we have to account wear & tear, interest part of the investments etc.

In the past, OEMs would concentrate on first cost, specifying lower efficiency less expensive motors and components. Users have demanded a more robust machine that increases productivity and lower life cycle cost. The life cost of a motor is only 2%; over 97% is energy cost.

In another discussion it was pointed out that some OEMs would choose the cheaper less efficient motors to use in thier products to gain a price advantage. So probably any rules would have to include having the motor efficiency information included in the product advertising materials. Sort of an enforcing of "truth in advertising", which I am sure would pain some folks a lot.

Industrial workplaces are governed by OSHA rules, but this isn’t to say that rules are always followed. While injuries happen on production floors for a variety of reasons, of the top 10 OSHA rules that are most often ignored in industrial settings, two directly involve machine design: lockout/tagout procedures (LO/TO) and machine guarding.

Load dump occurs when a discharged battery is disconnected while the alternator is generating current and other loads remain on the alternator circuit. If left alone, the electrical spikes and transients will be transmitted along the power line, leading to malfunctions in individual electronics/sensors or permanent damage to the vehicle’s electronic system. Bottom line: An uncontrolled load dump threatens the overall safety and reliability of the vehicle.

While many larger companies are still reluctant to rely on wireless networks to transmit important information in industrial settings, there is an increasing acceptance rate of the newer, more robust wireless options that are now available.

To those who have not stepped into additive manufacturing, get involved as soon as possible. This is for the benefit of your company. When the new innovations come out, you want to be ready to take advantage of them immediately, and that takes knowledge.

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